Rotor casting

Abstract

A rotor casting includes a lamination stack and a cast structure including proximal and distal cast end rings respectively adjacent proximal and distal end faces of the lamination stack. Cast axial ribs are distributed radially on a peripheral surface of the lamination stack and extend between the proximal and distal cast end rings. Cast feed members extend axially from the proximal cast end ring and are respectively positioned radially between an adjacent pair of axial ribs. In one example, cast bar segments integral to the proximal and distal cast end rings are formed in axial slots of the lamination stack. In one example, a bar insert in each axial slot has insert ends that extend respectively from the proximal and distal end faces of the lamination stack and are fully encapsulated respectively in the proximal and distal cast end rings. A method of forming the rotor casting is provided.

The invention claimed is: 
     
       1. A rotor casting comprising:
 a lamination stack having a proximal end face and a distal end face; 
 an axis of rotation defined by the lamination stack; 
 a cast structure comprising:
 a proximal cast end ring adjacent the proximal end face; 
 a distal cast end ring adjacent the distal end face; and 
 a plurality of cast axial ribs distributed radially on an external peripheral surface of the lamination stack relative to the axis of rotation; 
 
 wherein each of the plurality of cast axial ribs extends between the proximal cast end ring and the distal cast end ring; 
 wherein each of the plurality of axial ribs extends radially outward from the external peripheral surface of the lamination stack; and 
 wherein the cast structure incorporates the lamination stack. 
 
     
     
       2. The rotor casting of  claim 1 , further comprising:
 a plurality of axial slots defined by the lamination stack and distributed radially on the periphery of the lamination stack relative to the axis of rotation; 
 each of the axial slots extending between the proximal and distal end faces; 
 wherein the cast structure further comprises: 
 a plurality of cast bar segments formed in the plurality of slots of the lamination pack, each of the cast bar segments extending between and integral to the proximal and distal cast end rings. 
 
     
     
       3. The rotor casting of  claim 1 , wherein each respective cast axial rib includes a distal cast rib terminus extending radially from the distal cast end ring and a proximal cast rib terminus extending radially from the proximal cast end ring. 
     
     
       4. The rotor casting of  claim 1 , further comprising:
 a plurality of axial slots defined by the lamination stack and distributed radially on the periphery of the lamination stack relative to the axis of rotation; 
 each of the axial slots extending between the proximal and distal end faces; 
 a bar insert disposed in each of the plurality of axial slots; 
 wherein each bar insert includes first and second insert ends extending respectively from the proximal and distal end faces of the lamination stack. 
 
     
     
       5. The rotor casting of  claim 4 , wherein the first insert ends are fully encapsulated in the proximal cast end ring and the second insert ends are fully encapsulated in the distal cast end ring. 
     
     
       6. The rotor casting of  claim 5 , further comprising:
 wherein each of the first and second insert ends defines a hole; 
 wherein each respective hole is filled with cast material of the cast structure. 
 
     
     
       7. A rotor casting comprising:
 a lamination stack having a proximal end face and a distal end face; 
 an axis of rotation defined by the lamination stack; 
 a cast structure comprising:
 a proximal cast end ring adjacent the proximal end face; 
 a distal cast end ring adjacent the distal end face; and 
 a plurality of cast axial ribs distributed radially on an external peripheral surface of the lamination stack relative to the axis of rotation; 
 
 wherein each of the plurality of cast axial ribs extends between the proximal cast end ring and the distal cast end ring; 
 wherein the cast structure incorporates the lamination stack; and 
 wherein the cast structure further comprises a cast peripheral skin extending from the plurality of cast axial ribs to at least partially encapsulate the external peripheral surface of the lamination stack. 
 
     
     
       8. The rotor casting of  claim 7 , wherein each of the cast axial ribs extends radially from the cast peripheral skin. 
     
     
       9. A rotor casting comprising:
 a lamination stack having a proximal end face and a distal end face; 
 an axis of rotation defined by the lamination stack; 
 a cast structure comprising:
 a proximal cast end ring adjacent the proximal end face; 
 a distal cast end ring adjacent the distal end face; and 
 a plurality of cast axial ribs distributed radially on a peripheral surface of the lamination stack relative to the axis of rotation; 
 
 wherein each of the plurality of cast axial ribs extends between the proximal cast end ring and the distal cast end ring; 
 wherein the cast structure incorporates the lamination stack; and 
 wherein the cast structure further comprises a plurality of cast feed members extending axially from the proximal cast end ring. 
 
     
     
       10. The rotor casting of  claim 9 , wherein the plurality of cast feed members are distributed radially on the proximal cast end ring. 
     
     
       11. The rotor casting of  claim 9 , wherein each respective cast feed member is positioned radially between a respective adjacent pair of cast axial ribs.